MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7828-10
August 2010

Operation and
Maintenance
Manual
3406C Generator Set
ZKC1-Up (Generator Set)
C2G1-Up (Generator Set)
C5G1-Up (Generator Set)
C8G1-Up (Generator Set)
NKM1-Up (Generator Set)
C2Y1-Up (Generator Set)

SAFETY.CAT.COM
SEBU7828-10
i04002881
Maintenance Interval Schedule
(Prime)
SMCS Code: 1000; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for the
performance of all maintenance including the
following procedures: all adjustments, the use of
proper lubricants, fluids, filters, and the installation
of new components due to normal wear and aging .
The performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Products that operate in severe operating conditions
may require more frequent maintenance.
When Required
Battery - Recycle ................................................ 126
Battery - Replace ................................................ 126
Battery or Battery Cable - Disconnect ................ 128
Circuit Breakers - Reset ...................................... 129
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 135
Engine - Clean .................................................... 138
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................. 138
Ether Starting Aid Cylinder - Replace ................. 146
Fuel System - Prime ........................................... 146
Generator - Dry ................................................... 151
Generator Bearing - Lubricate ............................ 155
Generator Set - Test ........................................... 159
Generator Set Alignment - Check ....................... 160
Rotating Rectifier - Test ...................................... 171
Severe Service Application - Check ................... 172
Daily
Annunciator Panel - Inspect ................................ 123
Cooling System Coolant Level - Check .............. 133
Engine Air Cleaner Service Indicator - Inspect ... 141
Engine Oil Level - Check .................................... 142
Fuel System Primary Filter/Water Separator -
Drain ................................................................. 149
Generator Bearing Temperature - Test/Record ... 158
Generator Load - Check ..................................... 159
Power Factor - Check ......................................... 170
119
Maintenance Section
Maintenance Interval Schedule
Walk-Around Inspection ...................................... 176
Every Week
Electrical Connections - Check ........................... 137
Generator - Inspect ............................................. 153
Generator Lead (Flat Braided Cable) - Check .... 158
Instrument Panel - Inspect .................................. 164
Space Heater - Check ........................................ 173
Stator Winding Temperature - Measure/Record .. 174
Voltage and Frequency - Check ......................... 176
Every 2000 Service Hours
Generator Lead (Round Cable) - Check ............. 158
Every 2000 Service Hours or 6 Months
Generator Set Vibration - Test/Record ................ 161
Insulation - Test ................................................... 164
Stator Lead - Check ............................................ 174
Every Year
Alternator - Inspect ............................................. 123
Fan Drive Bearing - Lubricate ............................. 146
Generator Set Vibration - Inspect ....................... 160
Varistor - Check .................................................. 176
Varistor - Inspect ................................................. 176
Every 3 Years
Turbocharger - Inspect ........................................ 175
First 9500 L (2500 US gal) of Fuel or 250
Service Hours
Engine Valve Lash - Inspect/Adjust .................... 145
Every 9500 L (2500 US gal) of Fuel or 250
Service Hours or Yearly
Aftercooler Core - Clean/Test ............................. 123
Battery Electrolyte Level - Check ........................ 127
Belts - Inspect/Adjust/Replace ............................ 128
Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 134
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ............................................... 135
Engine Crankcase Breather - Clean ................... 141
Engine Oil Sample - Obtain ................................ 142
Engine Oil and Filter - Change ........................... 143
Fuel System Secondary Filter - Replace ............ 149
Fuel Tank Water and Sediment - Drain ............... 150
Hoses and Clamps - Inspect/Replace ................ 161
Magnetic Pickups - Clean/Inspect ...................... 167
Radiator - Clean .................................................. 170
Rotating Rectifier - Check ................................... 171
Every 19 000 L (5000 US gal) of Fuel or 250
Service Hours
Fan Drive Bearing - Lubricate ............................. 146
120 SEBU7828-10
Maintenance Section
Maintenance Interval Schedule

Every 19 000 L (5000 US gal) of Fuel or 500

Service Hours
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 148

Every 28 400 L (7500 US gal) of Fuel or 1000

Service Hours
Engine Protective Devices - Check .................... 145

Every 114 000 L (30 000 US gal) of Fuel or

3000 Service Hours or 2 Years
Cooling System Coolant (DEAC) - Change ........ 129
Cooling System Coolant Extender (ELC) - Add .. 132
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 135
Cooling System Water Temperature Regulator -
Replace ............................................................. 136
Crankshaft Vibration Damper - Inspect ............... 137
Engine Mounts - Inspect ..................................... 142
Engine Valve Lash - Inspect/Adjust .................... 145
Engine Valve Rotators - Inspect ......................... 145

Every 114 000 L (30 000 US gal) of Fuel or

3000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change ........ 129
Crankshaft Vibration Damper - Inspect ............... 137

Every 190 000 L (50 000 US gal) of Fuel or

5000 Service Hours
Alternator - Inspect ............................................. 123
Magnetic Pickups - Clean/Inspect ...................... 167
Starting Motor - Inspect ...................................... 174
Turbocharger - Inspect ........................................ 175
Water Pump - Inspect ......................................... 177

Every 228 000 L (60 000 US gal) of Fuel or 12

000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ........... 131

Overhaul
Generator Bearing - Inspect/Replace ................. 154
Overhaul Considerations .................................... 167
SEBU7828-10
i04002886
Maintenance Interval Schedule
(Standby)
SMCS Code: 1000; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for the
performance of all maintenance including the
following procedures: all adjustments, the use of
proper lubricants, fluids, filters, and the installation
of new components due to normal wear and aging .
The performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Products that operate in severe operating conditions
may require more frequent maintenance.
When Required
Battery - Recycle ................................................ 126
Circuit Breakers - Reset ...................................... 129
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 135
Ether Starting Aid Cylinder - Replace ................. 146
Fuel System - Prime ........................................... 146
Fuel System Primary Filter/Water Separator -
Drain ................................................................. 149
Generator Bearing - Lubricate ............................ 155
Generator Load - Check ..................................... 159
Generator Set - Test ........................................... 159
Rotating Rectifier - Test ...................................... 171
Every Week
Automatic Start/Stop - Inspect ............................ 125
Battery Charger - Check ..................................... 126
Battery Electrolyte Level - Check ........................ 127
Cooling System Coolant Level - Check .............. 133
Electrical Connections - Check ........................... 137
Engine Air Cleaner Service Indicator - Inspect ... 141
Engine Oil Level - Check .................................... 142
Fuel Tank Water and Sediment - Drain ............... 150
Generator - Inspect ............................................. 153
Generator Bearing Temperature - Test/Record ... 158
Generator Lead (Flat Braided Cable) - Check .... 158
Jacket Water Heater - Check .............................. 167
Power Factor - Check ......................................... 170
Space Heater - Check ........................................ 173
121
Maintenance Section
Maintenance Interval Schedule
Standby Generator Set Maintenance
Recommendations ............................................ 173
Stator Winding Temperature - Measure/Record .. 174
Voltage and Frequency - Check ......................... 176
Every 6 Months
Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 134
Generator Lead (Round Cable) - Check ............. 158
Stator Lead - Check ............................................ 174
Every Year
Alternator - Inspect ............................................. 123
Belts - Inspect/Adjust/Replace ............................ 128
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 135
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ............................................... 135
Crankshaft Vibration Damper - Inspect ............... 137
Engine - Clean .................................................... 138
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................. 138
Engine Crankcase Breather - Clean ................... 141
Engine Mounts - Inspect ..................................... 142
Engine Oil Sample - Obtain ................................ 142
Engine Oil and Filter - Change ........................... 143
Engine Performance - Test ................................. 144
Engine Protective Devices - Check .................... 145
Engine Valve Lash - Inspect/Adjust .................... 145
Fan Drive Bearing - Lubricate ............................. 146
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 148
Fuel System Secondary Filter - Replace ............ 149
Generator - Dry ................................................... 151
Generator Set Vibration - Inspect ....................... 160
Generator Set Vibration - Test/Record ................ 161
Hoses and Clamps - Inspect/Replace ................ 161
Insulation - Test ................................................... 164
Magnetic Pickups - Clean/Inspect ...................... 167
Radiator - Clean .................................................. 170
Starting Motor - Inspect ...................................... 174
Varistor - Check .................................................. 176
Varistor - Inspect ................................................. 176
Water Pump - Inspect ......................................... 177
Every 3 Years
Cooling System Coolant (DEAC) - Change ........ 129
Cooling System Coolant Extender (ELC) - Add .. 132
Cooling System Water Temperature Regulator -
Replace ............................................................. 136
Rotating Rectifier - Check ................................... 171
Turbocharger - Inspect ........................................ 175
Every 6 Years
Cooling System Coolant (ELC) - Change ........... 131
122 SEBU7828-10
Maintenance Section
Maintenance Interval Schedule

Every 190 000 L (50 000 US gal) of Fuel or

5000 Service Hours
Alternator - Inspect ............................................. 123

Commissioning
Generator Set Alignment - Check ....................... 160
SEBU7828-10 123
Maintenance Section
Aftercooler Core - Clean/Test

i01546702 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
1. Remove the core. Refer to the Service Manual the procedure.
for the procedure.
For more information on cleaning the core, consult
2. Turn the aftercooler core upside-down in order to your Caterpillar dealer.
remove debris.

i02676048
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
Alternator - Inspect
can attack the internal metals of the core and cause SMCS Code: 1405-040
leakage. Only use the recommended concentration of
cleaner. Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
3. Back flush the core with cleaner. connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
Caterpillar recommends the use of Hydrosolv order to ensure proper battery performance and/or
liquid cleaner. Table 24 lists Hydrosolv liquid proper performance of the electrical system. Make
cleaners that are available from your Caterpillar repairs, as required.
dealer.
Check the alternator and the battery charger for
Table 24 proper operation. If the batteries are properly
Hydrosolv Liquid Cleaners(1) charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Part batteries should be kept warm because temperature
Description Size
Number affects the cranking power. If the battery is too cold,
1U-5490 Hydrosolv 4165 19 L (5 US gallon) the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
174-6854 Hydrosolv 100 19 L (5 US gallon) When the engine is not run for long periods of time
(1) Use a two to five percent concentration of the cleaner or if the engine is run for short periods, the batteries
at temperatures up to 93°C (200°F). Refer to Application may not fully charge. A battery with a low charge will
Guide, NEHS0526 or consult your Caterpillar dealer for more freeze more easily than a battery with a full charge.
information.

4. Steam clean the core in order to remove any i01148030

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Annunciator Panel - Inspect
SMCS Code: 4490-040
Inspect the annunciator panel for good condition.
Perform a lamp test. All of the warning lamps should
illuminate. If a warning lamp does not illuminate,
replace the bulb immediately. If the alarm does
not sound, investigate the problem and correct the
problem.
Check the condition of all of the gauges. If a gauge
is broken, repair the gauge or replace the gauge
immediately.
Frequently monitor the following parameters during
normal engine operation:
• Engine Oil Pressure
• Engine Coolant Temperature
124 SEBU7828-10
Maintenance Section
Annunciator Panel - Inspect

• Inlet Air Restriction

• Exhaust Temperature
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
the new data to the recorded data will establish the
normal gauge readings for the engine. A gauge
reading that is abnormal may indicate a problem with
engine operation. Abnormal gauge readings may
also indicate a possible problem with the gauge.

Record the Performance of the

Engine
Table 25 is offered as an example for use as a daily
engine log. Record the engine performance regularly.
Retain the recorded information for reference.
Compare the recorded data in order to provide an
indication of engine condition.

Records of engine performance are an important

element of a maintenance program. Record
information about the engine operation on a daily
basis. This will help to reveal the trends of the engine
performance. Records of engine performance will
also provide a baseline for evaluating the mechanical
condition of the engine.

The data on engine performance can help to predict

problems with operation. This data can provide
your Caterpillar dealer with information that is
useful for recommending maintenance management
information. A maintenance program that is properly
managed will provide your engine with an optimum
service life.
SEBU7828-10 125
Maintenance Section
Automatic Start/Stop - Inspect

Table 25
Daily Engine Log
Date

Authorization

Engine Serial Number

Engine Hours

Engine Speed

Percent Load

Ambient Temperature

Inlet Air Restriction

Engine Coolant Temperature

Engine Oil Temperature

Engine Oil Pressure

System Battery Voltage

Exhaust Manifold Temperature

Generator Voltage

Generator Amperage

Comments

i01942284 • The control switches are in the correct position for

automatic starting.
Automatic Start/Stop - Inspect
• The switchgear and the automatic transfer switches
SMCS Code: 4462 that are associated with the generator are enabled.
The generator set must be ready to operate under a
load at any time. After performing maintenance on
the generator set, inspect the position of the control
switches. Ensure the following conditions:

• The starting system is enabled.

126
Maintenance Section
Battery - Recycle
i02039199
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Return used batteries to one of the following
locations:
• A battery supplier
• An authorized battery collection facility
• A recycling facility
i02153996
Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE “-” battery terminal.
SEBU7828-10
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
i01917570
Battery Charger - Check
SMCS Code: 1401-535
Checking Before Start-Up
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of the
ammeter will register near “0” (zero).
The battery charger must not produce excessive
current during start-up. Alternatively, the charger
must be automatically disconnected for start-up.
If the engine has an alternator, the charger must
be automatically disconnected during start-up and
during engine operation.
Charging the Battery
Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
sonnel can be the result.
Perform the following procedure to charge the
battery:
1. Ensure that the charger is turned OFF.
SEBU7828-10 127
Maintenance Section
Battery Electrolyte Level - Check

2. Adjust the voltage of the charger in order to match Table 26

the voltage of the battery. Effects of Overcharging Batteries
3. Connect the POSITIVE “+” lead of the charger Type of Battery Effect
to the POSITIVE “+” battery terminal. Connect
the NEGATIVE “-” lead of the charger to the
NEGATIVE “-” battery terminal. Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Caterpillar Premium High
4. Turn ON the battery charger. Output Batteries
Overcharging of Batteries

Overcharging reduces the service life of batteries. When the plates of the
Use a battery charger that will not overcharge the battery are inspected
battery. DO NOT charge the battery if the meter of through the filler holes, the
the battery charger is in the RED zone. plates may appear to be
warped. This is caused by
Overcharging is indicated by the following symptoms: an excessive temperature.
The battery may not pass
• The battery is very warm to the touch. a load test.

• A strong odor of acid is present. Caterpillar Maintenance The battery may not accept
Free Batteries a charging current.
• The battery emits smoke or a dense vapor (gas). The battery may not pass
a load test.
Perform one of the following procedures if the battery
shows symptoms of overcharging:
Checking After Stopping
• Reduce the rate of charging by a significant
amount. Complete the charging at the reduced Ensure that the battery charger is connected
rate. properly. Observe the meter of the charger. Record
the amperage.
• Turn OFF the charger.
Table 26 describes the effects of overcharging on i02601752

different types of batteries. Battery Electrolyte Level -

Check
SMCS Code: 1401-535

When the engine is not run for long periods of time or

when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled

water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
128 SEBU7828-10
Maintenance Section
Battery or Battery Cable - Disconnect

2. Check the condition of the electrolyte with the i02200198

245-5829 Coolant Battery Tester Refractometer.
Belts - Inspect/Adjust/Replace
3. Keep the batteries clean.
SMCS Code: 1357-025; 1357-040; 1357-510
Clean the battery case with one of the following
cleaning solutions: Inspection
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -

Disconnect
SMCS Code: 1402-029
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
g00750216
Illustration 82
The belt cover must be removed for inspection, adjustment and
replacement.
(1) Mounting bolts
(2) Adjustment bolt
(3) Typical belt tension gauge
To maximize the engine performance, inspect the
belt for wear and for cracking. Check the belt tension.
Adjust the belt tension in order to minimize belt
slippage. Belt slippage will decrease the life of the
belt.
For the correct tension on the belt, refer to
Specifications, “Belt Tension Chart”.
Adjustment
1. Remove the belt cover.
2. Loosen mounting bolts (1) and adjusting bolt (2).
3. Slide the alternator in the direction that will give
the correct tension.

3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
4. Tighten adjusting bolt (2). Tighten mounting
bolts (1). For the proper torque, refer to the
Specifications Manual, SENR3130, “Torque
Specifications”.
5. Reinstall the belt cover.
SEBU7828-10
If new belts are installed, check the belt adjustment
again after 30 minutes of engine operation at the
rated rpm.
Replacement of Multiple Drive Belts
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
more load because the older belts are stretched. The
additional load on the new belt could cause the new
belt to break.
i02456186
Circuit Breakers - Reset
SMCS Code: 1417-529; 1420-529
Illustration 83
g01225779
Push in on the circuit breaker in order to reset the
circuit breaker.
(A) 60 Amp Circuit Breaker – This circuit breaker
is for the battery charger and the circuit for the
alternator.
(B) 15 Amp Circuit Breaker – This circuit breaker is
for the Electronic Control Module (ECM).
(C) 20 Amp Circuit Breaker – This circuit breaker is
for the control panel.
i02139869
Cooling System Coolant
(DEAC) - Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
129
Maintenance Section
Circuit Breakers - Reset
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
Note: If equipped, be sure to drain the heater and
any related supply and return lines.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Group:
130
Maintenance Section
Cooling System Coolant (DEAC) - Change
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 30 minutes. The coolant temperature should be
at least 82 °C (180 °F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to
flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
SEBU7828-10
Cooling Systems with Heavy
Deposits or Plugging
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris.
Note: If equipped, be sure to flush the heater and
any related supply and return lines.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82 °C (180 °F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
SEBU7828-10
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance Manual,
“Refill Capacitites and Recommendations” topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform
the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure,
install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i02215595
Cooling System Coolant (ELC)
- Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
131
Maintenance Section
Cooling System Coolant (ELC) - Change
• The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
Note: If equipped, be sure to flush the heater and
any related supply and return lines.
132 SEBU7828-10
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. For the
proper torque, refer to the Specifications Manual,
SENR3130, “Torque Specifications”.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. For the proper torque, refer to
the Specifications Manual, SENR3130, “Torque
Specifications”.
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i02482066
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
needs to be added once.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.

1. Fill the cooling system with Extended Life Coolant Do NOT use conventional supplemental coolant addi-
(ELC). See Special Publication, SEBU6251, tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
“Caterpillar Commercial Diesel Engine Fluids tional coolants and/or conventional SCA reduces the
Recommendations” for more information on Cat ELC service life.
cooling system specifications. Do not install the
cooling system filler cap. Check the cooling system only when the engine is
stopped and cool.
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level

within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
SEBU7828-10 133
Maintenance Section
Cooling System Coolant Level - Check

i01197583

Cooling System Coolant Level

Personal injury can result from hot coolant, steam
and alkali. - Check
At operating temperature, engine coolant is hot SMCS Code: 1395-082
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or Check the coolant level when the engine is stopped
steam. Any contact can cause severe burns. and cool.

Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.

Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

NOTICE g00285520
Care must be taken to ensure that fluids are contained Illustration 84
during performance of inspection, maintenance, test- Cooling system filler cap
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Refer to Special Publication, NENG2500, “Caterpillar
stop the engine and wait until the cooling system
Dealer Service Tool Catalog” for tools and supplies
components are cool. Loosen the cooling system
suitable to collect and contain fluids on Caterpillar
pressure cap slowly in order to relieve the pres-
products.
sure.
Dispose of all fluids according to local regulations and
mandates. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling 2. Maintain the coolant level within 13 mm (0.5 inch)
system filler cap. of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
2. It may be necessary to drain enough coolant from level to the proper level in the sight glass.
the cooling system in order to add the Cat ELC
Extender.

3. Add Cat ELC Extender according to the

requirements for your engine's cooling system
capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.

4. Clean the cooling system filler cap. Inspect the

gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.

g00103639
Illustration 85
Typical filler cap gaskets
134 SEBU7828-10
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.
i04035949
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems filled
with Cat ELC should have a Coolant Sample (Level
2) that is obtained at the recommended interval as
stated in the maintenance interval schedule.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC including the following
coolants:
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
• Cat DEAC (Diesel Engine Antifreeze/Coolant)
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish
a consistent trend of data. In order to establish
a pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your
Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic
bags.

• Commercial heavy-duty coolant/antifreeze • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
Table 27 from any other location.
Recommended Interval
• Keep the lids on empty sampling bottles until you
Type of Coolant Level 1 Level 2 are ready to collect the sample.
Cat DEAC
• Place the sample in the mailing tube immediately
Conventional after obtaining the sample in order to avoid
heavy duty- contamination.
coolant
Every 250 • Never collect samples from expansion bottles.
Commercial Every year(1)
service hours
coolant that
meets the • Never collect samples from the drain for a system.
requirements
of the Caterpillar Submit the sample for Level 1 analysis.
EC-1 standard
Cat ELC or
For additional information about coolant analysis,
conventional Optional Every year(1) see this Operation and Maintenance Manual, “Refill
EC-1 coolant Capacities and Recommendations” or consult your
(1)
Caterpillar dealer.
The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
SEBU7828-10
i01987714
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant
analysis, see Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer.
i02456600
Cooling System Supplemental
Coolant Additive (SCA) -
Test/Add
SMCS Code: 1352-045; 1395-081
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis.
Test for SCA Concentration
Coolant and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
135
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Use the 8T-5296 Coolant Conditioner Test Kit
or use the 4C-9301 Coolant Conditioner Test Kit
in order to check the concentration of the SCA.
Refer to this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” for more
information.
Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Refer to the Special
Publication, SEBU6251, “Caterpillar Commercial
Diesel Engine Fluids Recommendations” for more
information.
S·O·S Coolant Analysis
S·O·S coolant samples can be analyzed at your
Caterpillar dealer. S·O·S Coolant Analysis is a
program that is based on periodic samples.
Level 1
Level 1 is a basic analysis of the coolant. The
following items are tested:
• Glycol Concentration
• Concentration of SCA
• pH
• Conductivity
The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an S·O·S Coolant
Analysis.
Level 2
This level coolant analysis is recommended when the
engine is overhauled. Refer to this Operations and
Maintenance Manual, “Overhaul Considerations” for
further information.
136
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Add the SCA, If Necessary
NOTICE
Do not exceed the recommended amount of sup-
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temper-
ature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concen-
tration exceeding the recommended maximum.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to
local regulations.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA.
3. Add the proper amount of SCA. Refer
to the Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engines Fluids
Recommendations” for more information on SCA
requirements.
4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
SEBU7828-10
i03645060
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for the proper maintenance
interval.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulators
- Remove and Water Temperature Regulators -
Install” for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
SEBU7828-10
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i00894991
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train
noise at variable points in the speed range.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.
Rubber Damper
Your engine may be equipped with a rubber damper.
The rubber damper uses a ring which is mounted in
rubber in order to reduce vibrations in the crankshaft.
Inspect the damper and repair or replace the damper
for any of the following reasons:
• There is deterioration and cracking of the rubber.
• There is slippage of the outer ring from the original
position.
• The engine has had a failure because of a broken
crankshaft.
• Analysis of the oil has revealed that the front main
bearing is badly worn.
• There is a large amount of gear train wear that is
not caused by lack of oil.
Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
replacement.
Visconic Damper
Your engine may be equipped with a visconic
damper. The visconic damper has a weight that is
located inside a fluid filled case. The weight moves in
the case in order to limit torsional vibration.
137
Maintenance Section
Crankshaft Vibration Damper - Inspect
Inspect the damper for evidence of fluid leaks. If
a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and difficult to remove from surfaces.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
Inspect the damper and repair or replace the damper
for any of the following reasons:
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• Analysis of the oil has revealed that the front main
bearing is badly worn.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
replacement.
i01228274
Electrical Connections - Check
SMCS Code: 4459-535
Check all exposed electrical connections for
tightness.
Check the following devices for loose mounting or
for physical damage:
• transformers
• fuses
• capacitors
• lightning arrestors
Check all lead wires and electrical connections for
proper clearance.
138
Maintenance Section
Engine - Clean
i01866598
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high volt-
age.
Moisture could create paths of electrical conduc-
tivity.
Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
tagged "Do Not Operate".
NOTICE
Water or condensation can cause damage to gen-
erator components. Protect all electrical components
from exposure to water.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Do not steam clean the generator. Water may
damage the generator.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
i01553486
Engine Air Cleaner Element
(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
SEBU7828-10
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
• Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt
and debris, as needed.
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
element.
• The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
inspected.
• The air cleaner element should be replaced at least
one time per year. This replacement should be
performed regardless of the number of cleanings.
Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
Dual Element Air Cleaners
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
SEBU7828-10 139
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air Cleaner

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.
g00736431
Illustration 86
(1) Cover Do not wash the filter element.
(2) Primary air cleaner element
(3) Secondary air cleaner element Use low pressure compressed air in order to remove
(4) Turbocharger air inlet
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
1. Remove the cover. Remove the primary air pleats and down the pleats from the inside of the filter
cleaner element. element. Take extreme care in order to avoid damage
to the pleats.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings Do not use air filters with damaged pleats, gaskets, or
of the primary air cleaner element. seals. Dirt entering the engine will cause damage to
engine components.
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”.
The primary air cleaner element can be used up
3. Cover the turbocharger air inlet with tape in order to six times if the element is properly cleaned and
to keep dirt out. inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
4. Clean the inside of the air cleaner cover and body The primary air cleaner element should be replaced
with a clean, dry cloth. at least one time per year. This replacement should
be performed regardless of the number of cleanings.
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a Use clean primary air cleaner elements while dirty
primary air cleaner element that is new or cleaned. elements are being cleaned.

6. Install the air cleaner cover. NOTICE

7. Reset the air cleaner service indicator.
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the primary air cleaner elements

before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.

There are two common methods that are used to

clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning
140
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
g00281692
Illustration 87
Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced further into the pleats.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
SEBU7828-10
Inspecting the Primary Air Cleaner
Elements
g00281693
Illustration 88
Inspect the clean, dry primary air cleaner element.
Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements
If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
be stored for future use.
g00281694
Illustration 89
SEBU7828-10
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i01900118
Engine Air Cleaner Service
Indicator - Inspect
(If Equipped)
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.
g00103777
Illustration 90
Typical service indicator
141
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
Test the Service Indicator
Service indicators are important instruments.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 N·m (18 lb in).
i01564253
Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
142
Maintenance Section
Engine Mounts - Inspect
g00812591
Illustration 91
Typical example
(1) Hose clamp
(2) Cover clamp
(3) Crankcase breather cover
1. Loosen hose clamp (1) and remove the hose from
crankcase breather (2).
2. Remove the crankcase breather (2).
3. Wash the breather element in solvent that is clean
and nonflammable. Allow the breather element to
dry before installation.
4. Install a breather element that is clean and dry.
Install the crankcase breather (2). Refer to the
Operation and Maintenance Manual for the proper
torque.
5. Install the hose. Install hose clamp (1). Refer to
the Operation and Maintenance Manual for the
proper torques.
i02139969
Engine Mounts - Inspect
SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine
• Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.
SEBU7828-10
i00623423
Engine Oil Level - Check
SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
g00110310
Illustration 92
(Y) “ADD” mark. (X) “FULL” mark.
NOTICE
Perform this maintenance with the engine stopped.
1. Maintain the oil level between “ADD” mark (Y) and
“FULL” mark (X) on oil level gauge (1). Do not fill
the crankcase above “FULL” mark (X).
NOTICE
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
i03542996
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
SEBU7828-10
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
143
Maintenance Section
Engine Oil and Filter - Change
For instructions, see Special Publication, PEgj0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i02107152
Engine Oil and Filter - Change
SMCS Code: 1318-510; 1348-044
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
• If the engine is equipped with a drain valve, turn the
drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
After the oil has drained, the oil drain plugs should
be cleaned and installed.
144
Maintenance Section
Engine Performance - Test
Replace the Oil Filter
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
1. Remove the oil filter with a 1U-8760 Chain
Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
g00103713
Illustration 93
Typical filter mounting base and filter gasket
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
removed.
4. Apply clean engine oil to the new oil filter gasket.
SEBU7828-10
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.
Fill the Engine Crankcase
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” for more information.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.
i01042067
Engine Performance - Test
SMCS Code: 1000-081
Operate the engine for a minimum of two hours at a
minimum load of 60 percent.
• Monitor the operation of the generator set.
• Observe the gauges. Ensure that the gauges are
in the normal ranges.
SEBU7828-10
• Record the data. Maintain a record of the data for
the engine performance.
i00626013
Engine Protective Devices -
Check
SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
i03840829
Engine Valve Lash -
Inspect/Adjust
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
valve train components.
145
Maintenance Section
Engine Protective Devices - Check
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge
Adjustment” article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Ensure that the engine cannot be started while this
maintenance is being performed. To help prevent
possible injury, do not use the starting motor to
turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
performed.
Refer to the Service Manual for more information.
i01597115
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
146 SEBU7828-10
Maintenance Section
Ether Starting Aid Cylinder - Replace

2. Operate the engine at low idle. i02784507

3. Observe the top surface of each valve rotator. The Fan Drive Bearing - Lubricate
valve rotators should turn slightly when the valves
close. SMCS Code: 1359-086-BD

Some of the fan drives have grease fittings and some

NOTICE
of the fan drives do not have grease fittings. If there is
A valve rotator which does not operate properly will
no grease fitting, periodic lubrication is not required.
accelerate valve face wear and valve seat wear and
The fan drive requires grease only if the fan drive
shorten valve life. If a damaged rotator is not replaced,
is equipped with a zerk.
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.

If a valve fails to rotate, consult your Caterpillar

dealer.

i00805059

Ether Starting Aid Cylinder -

Replace
(If Equipped)
SMCS Code: 1456-510-CD Illustration 95
g00746166

Typical location of the grease fitting (if equipped) that is for the fan
drive bearing
The pulley is shown with the belt guards that have been removed.

Lubricate the grease fitting that is on the fan drive

bearing with High Speed Ball Bearing Grease or the
equivalent.

Inspect the fan drive pulley assembly for wear or for

damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Systems Operation Testing and Adjusting Manual
for additional information.

g00104888
Illustration 94
i00891826
Typical example
Fuel System - Prime
1. Loosen the ether cylinder clamp. Unscrew and
remove the empty ether cylinder. SMCS Code: 1258-548

2. Remove the used gasket. Install the new gasket

that is provided with each new ether cylinder.
3. Install the new ether cylinder. Hand tighten the
ether cylinder. Tighten the ether cylinder clamp
securely.
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.

Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.
SEBU7828-10 147
Maintenance Section
Fuel System - Prime

Prime the fuel system in order to fill dry fuel filters.
You must also prime the fuel system after any one of
the following conditions exist:
• The fuel system has run dry.
• The engine has been in prolonged storage.
• The fuel filter has been cleaned.
• The fuel filter has been replaced.
Note: If the engine does not have a fuel priming
pump, refer to Step 4.
1. Unlock the priming pump, and operate the priming
pump until a resistance is felt. This procedure
will probably require a considerable amount of
priming.
2. Push in the plunger, and hand tighten the plunger.
7. Crank the engine. If the engine starts and if the
engine runs rough, run the engine at low idle.
Continue running the engine until the engine runs
smoothly.
Note: If the engine will not start, more priming is
necessary. If the engine continues to run rough, more
priming is necessary as well.
NOTICE
Do not let the tops of fuel nozzles turn when the fuel
line nuts are loosened or tightened.
The nozzles will be damaged if the top of the nozzle
turns in the body.
The engine will be damaged if a defective fuel injec-
tion nozzle is used because the shape of fuel (spray
pattern) that comes out of the nozzles will not be cor-
rect.

NOTICE
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
that the oil pressure is sufficient.

3. Crank the engine.

If the engine starts and the engine runs rough,

run the engine at low idle. Continue running the
engine until the engine runs smoothly.
g00290109
Illustration 96
NOTICE
During periodic service, DO NOT remove the fuel filter 8. Loosen the fuel line nuts at the valve cover base.
plug that is in the fuel filter base in order to purge air Loosen these line nuts one at a time.
from the fuel system. The periodic removal of the fuel
filter plug will result in increased wear on the threads 9. Operate the priming pump until the flow of fuel
in the fuel filter base. This wear leads to fuel leakage. from the fuel line is continuous and the flow of fuel
is free of air bubbles.
4. Open the vent valve (if equipped) on the fuel
10. Push in the plunger, and hand tighten the plunger.
injection pump's housing.
If the engine does not have a fuel priming pump,
crank the engine.
5. Operate the priming pump until the flow of fuel
from the vent valve is continuous and the flow of
11. Tighten each fuel line nut before you loosen the
fuel is free of air bubbles.
next fuel line nut. Tighten the fuel line nuts to a
torque of 40 ± 7 N·m (30 ± 5 lb ft).
If the engine does not have a fuel priming pump,
crank the engine. Crank the engine until the fuel
Continue this procedure until all of the fuel lines
flows freely and until the fuel is free of air bubbles.
have been cleared of any air. Before you start
the engine, make sure that the fuel line nuts
6. Close the vent valve. Then, push in the plunger.
are properly tightened. Also make sure that the
Hand tighten the plunger.
priming is locked.
148
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i02049797
Fuel System Primary Filter
(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. Install a vacuum gauge. Change the
element for the primary filter/water separator if the
pressure is at 50 to 70 kPa (15 to 20 inches Hg).
Replace the Element
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
g00668636
Illustration 97
(1) Bowl
(2) Element
(3) Drain
1. Stop the engine.
2. Turn the start switch to the “OFF” position.
3. Shut off the fuel tank supply valve to the engine.
4. If the primary fuel filter is equipped with a drain
valve (3), open the drain valve in order to drain any
fuel from the filter case. Close the drain valve (3).
SEBU7828-10
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
5. Remove the fuel filter bowl (1) and wash the fuel
filter bowl with clean diesel fuel.
6. Remove the fuel filter (2).
7. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
8. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel,
use Caterpillar fuel filters.
Consult your Caterpillar dealer for proper part num-
bers.
9. Install the new fuel filter (2). Spin the fuel filter
onto the fuel filter base until the gasket contacts
the base. Use the rotation index marks on the
filters as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
10. Install the clean fuel filter bowl (1) on the new fuel
filter.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
11. Open the fuel tank supply valve.
12. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check
the engine for leaks again.
Detection of leaks is very difficult especially if
the engine is running. The primary filter/water
separator is under suction. A leak will allow air to
enter the fuel. The air in the fuel can cause low
power due to aeration of the fuel. If air enters the
fuel, check the components for overtightening or
undertightening.
SEBU7828-10 149
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i01254694

Fuel System Primary

Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543

g00410343
Illustration 99
(1) Fuel priming pump
(2) Fuel filter
(3) Fuel block
(4) Fuel filter air purge plug

Illustration 98
g00668636 NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
(1) Bowl
(2) Element
clean the area around a fuel system component that
(3) Drain will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
Bowl (1) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
NOTICE
1. Open drain (3). The drain is a self-ventilated drain. Use a suitable container to catch any fuel that might
Catch the draining water in a suitable container. spill. Clean up any spilled fuel immediately.
Dispose of the water properly.
1. It may be necessary to relieve residual fuel
2. Close drain (3). pressure from the fuel system before removing
the fuel filter.
NOTICE
The water separator is under suction during normal Loosen the fuel filter air purge plug (4) in order to
engine operation. Ensure that the drain valve is tight- purge any residual pressure.
ened securely to help prevent air from entering the fuel
system. NOTICE
Do not loosen fuel lines or fittings at the fuel manifold
or ECM. The engine components may be damaged.
i01250684

Fuel System Secondary Filter - 2. Remove the used fuel filter.

Replace 3. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
SMCS Code: 1261-510-SE
4. Apply clean diesel fuel to the new fuel filter gasket.

Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
In order to maximize fuel system life and prevent
premature wear out from abrasive particles in the
fuel, a two micron absolute high efficiency fuel filter
is required for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.
150
Maintenance Section
Fuel Tank Water and Sediment - Drain
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
5. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.
6. Open the fuel tank supply valve and prime the fuel
system.
i03645042
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
SEBU7828-10
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Note: Failure to properly close the drain can allow air
into the system, which could have detrimental results
to performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Oil change
• Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended. Refer
to Special Publication, SENR9620, “Improving Fuel
System Durablity”.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
SEBU7828-10
i03997990
Generator - Dry
SMCS Code: 4450-569
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
Refer to this Operation and Maintenance Manual,
“Generator Isolating for Maintenance” for information
regarding the procedure to isolate the generator in
a safe manner.
Refer to Special Instruction, REHS9124, “Cleaning
and Drying of the Generator” for further necessary
information.
Of the following methods for drying the generator, the
use of external heat is preferred.
• External heat
• Internal heat
• Combination of external and internal heat
• Circulating current
External heat is the most preferable method.
Insulation drying time can vary from a few hours
to several days. The drying time depends on the
moisture content and the process for drying that is
used.
Note: Drying sometimes does not produce the
required results. The use of a qualified rebuild
shop may be necessary for dipping and drying the
generator.
151
Maintenance Section
Generator - Dry
g02175752
Illustration 100
Typical curves of the resistance in the insulation that is drying
(1) Curve of the temperature in the windings
(2) Heat turned off.
(3) Drying time in hours
(4) Temperature in degrees celsius
(5) Curve of insulation resistance during drying process
(6) Insulation resistance in megohms
Note: When new insulation or very damp insulation
is being dried, the resistance will probably fall
rapidly. The rapid fall in resistance is the result of the
temperature being raised to a value for drying. After
reaching a minimum for a given temperature, the
resistance will again rise as moisture is driven out of
the insulation. The actual values will vary with each
situation. Refer to Illustration 101.
If the windings or insulation are wet during the
resistance measurement, use a 5 megohm resistor
for protection in series with red positive lead. This
procedure limits the voltage across the circuit
under the test. Use this method until drying is well
in progress and the resistance has reached an
acceptable level.
Check the windings after every 4 hours when either
external or internal heat is used to dry the generator.
Check the windings very hour when circulating
current is used to dry the generator. Refer to Special
Instruction, REHS9124, “Cleaning and Drying of the
Generator” for more information.
Drying is complete when the tests show no increase
in resistance and the resistance is above the
minimum. Record these readings and compare these
readings. Keep these records for future reference.
152
Maintenance Section
Generator - Dry
g01696934
Illustration 101
Curve of insulation resistance for windings in good condition
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 101 indicates the curve of the resistance
of a normal high resistance in the windings over
a period of 60 seconds. The resistance after 60
seconds will be greater than the resistance or equal
to the resistance after 30 seconds .
Note: If the insulation resistance after 60 seconds is
not higher than the resistance after 30 seconds , the
insulation may be weak.
g01697074
Illustration 102
Curve of insulation resistance for windings that are wet or dirty
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 102 indicates the curve of the resistance
that is decaying over a period of 60 seconds. If the
insulation resistance after 60 seconds is not higher
than the resistance after 30 seconds , clean the
windings and thoroughly dry the windings. Refer
to Special Instruction, REHS9124, “Cleaning and
Drying of the Generator” for more information.
SEBU7828-10
Note: Caterpillar recommends a minimum acceptable
insulation resistance of 1 megohm for generators
which operate with less than 1000 V of operating or
rated voltage. Generators which operate at 1000 V
of operating or rated voltage should have a minimum
insulation resistance as determined by the following
equation:
R = (V/1000) + M
“R” is the minimum insulation resistance.
“V” is the rated voltage.
“M” is 1 megohm.
These values are approximate. It may be possible to
operate a generator with less resistance.
External Heat
Ovens
The best oven is a forced air drying oven for drying
electrical equipment. Radiant ovens sometimes
cause localized overheating.
NOTICE
Do not heat the generator too quickly. Try to limit the
rise in temperature of the insulation and windings to
11.11° C (20° F) per hour. Failure to do so may cause
equipment damage.
Note: Many electrical shops are equipped with
baking ovens.
Heat the generator to approximately 75° C (167° F).
Never exceed 75° C (167° F) until the insulation
tester tests correctly for insulation resistance (at least
4 hours).
Alternate Method
A tent formed by a tarp or a canvas with heated
lamps or a portable space heater may be used as
an alternate method.
A hole should be left in the top of the tarp for
ensuring proper circulation through the generator
and for permitting the moisture to exhaust. Heat the
generator to approximately 75° C (167° F). Never
exceed 75° C (167° F) until the insulation tester tests
correctly for insulation resistance (at least 4 hours).
Internal Heating
If generators operate under one of the following
conditions, the electric space heaters should be
installed as part of the generator:
SEBU7828-10
• Generators are in damp environments and go for
long periods of time without operation.
• Generators operate regularly in an environment
with moisture laden air.
Circulating Current
Drying can be accomplished by circulating low
voltage current through the windings. Since the
voltage is low, the breakdown of the insulation will not
occur as the breakdown might have occurred with
normal operation and wet insulation. Refer to Special
Instruction, REHS9124, “Cleaning and Drying of the
Generator” for this procedure.
i01461264
Generator - Inspect
SMCS Code: 4450-040
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure
to safely isolate the generator.
Proper maintenance of electrical equipment requires
periodic visual examination of the generator and
periodic visual examination of the windings. Proper
maintenance of electrical equipment also requires
appropriate electrical checks and appropriate thermal
checks. Insulation material should be examined for
cracks. The insulation material should be examined
for accumulations of dirt and dust. If there is an
insulation resistance value that is below normal, a
conductive path may be present. This conductive
path may be made of one of the following materials:
• Carbon
• Salt
• Metal dust
• Dirt that is saturated with moisture
153
Maintenance Section
Generator - Inspect
These contaminants will develop a conductive path
which may produce shorts. Cleaning is advisable if
heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
the cause of a restriction in the ventilation, cleaning
is also advisable. Restricted ventilation will cause
excessive heating.
NOTICE
To avoid the possibility of deterioration to the genera-
tor windings, do not clean the generator unless there
is visual, electrical, or thermal evidence that dirt is
present.
If harmful dirt accumulations are present, a variety
of cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
• The extent of the cleaning procedure that is being
attempted
• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed
Cleaning (Assembled Generators)
Cleaning may be required at the point of installation.
At this point, complete disassembly of the generator
may not be necessary or feasible. In this case,
a vacuum cleaner should be used to pick up the
following items: dry dirt, dust, and carbon. This will
prevent the spreading of these contaminants.
A small nonconductive tube may need to be
connected to the vacuum cleaner. This will allow the
vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed,
a small brush may be attached to the vacuum hose
in order to loosen dirt that is more firmly attached to
the surface.
After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the
above cleaning procedures are not effective, consult
a Caterpillar dealer.
154 SEBU7828-10
Maintenance Section
Generator Bearing - Inspect/Replace

Cleaning (Disassembled Inspect

Generators) 1. Remove the bearing bracket. Inspect the following
items: bracket bore, bearing outer race, and
An initial insulation resistance check should be
rolling elements. On standby power units, the
made on the generator in order to confirm electrical
bearing must be inspected and the grease must
integrity. A minimum reading of one megohm would
be replaced at three year intervals. The sleeve
be expected with severely contaminated generators.
in the bearing bracket should be inspected for
A zero megohm reading may indicate an insulation
out of roundness, excessive wear, and a bracket
breakdown. An insulation breakdown requires more
step that is less than 0.0762 mm (0.0030 inch). If
than cleaning. An insulation breakdown requires
there is no sleeve in the bearing bracket, inspect
repair.
the bore of the bearing bracket. The bearing
should be inspected for damage to the outer race,
A high pressure wash is normally an effective way
severe fretting, and smoothness of operation.
to clean windings. This includes windings that have
When possible, the bearing elements should be
been exposed to flooding or windings that have been
inspected. Some double shielded ball bearings
contaminated by salt. A solution of hot water and
prevent visual inspection of the elements of the
detergent is used for this method of cleaning.
bearing. Other double shielded ball bearings
have a retaining ring. This retaining ring can be
A high pressure wash sprays a high velocity fluid
removed in order to allow access for a visual
stream of this solution over the generator that is
inspection of the elements of the bearing.
being cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
On two-bearing generators, the front bearing
used in order to remove the detergent or the clean
can only be removed after the drive coupling
water is used in order to dilute the detergent.
is removed. Refer to the Systems Operation
Testing and Adjusting Disassembly and Assembly,
Allow the generator to dry at room temperature.
“Coupling - Remove” for the generator for
Check the insulation resistance. The insulation
instructions for removing the drive coupling.
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It
may be necessary to use solvents if the generator Replace
is contaminated with oil or if the generator is
contaminated with grease. 1. All ball bearings should be cleaned. The cavity
in the bracket should be repacked with 2S-3230
Note: For more information on drying methods, refer Grease. Pack the ball bearings (one-third to
to Special Instructions, SEHS9124, “Cleaning and one-half of the volume of the cavity).
Drying of Electric Set Generators”.
2. Use an induction heater to heat the ball bearings to
107 °C (224.6 °F) for ten minutes in order to install
i03099722
either of the following bearings: ball bearings
Generator Bearing - that are new and ball bearings that have been
inspected. Mount the bearings on the shaft. To
Inspect/Replace reinstall the hub, heat the hub to 400 °C (752.0 °F)
(SR4 Generator) for three hours. Mount the hub to the shaft.

3. Ensure that the tube of the grease gun is filled

SMCS Code: 4471-040; 4471-510
with grease.
The following maintenance procedure for generator
4. Remove the bracket drain plug and operate the
bearings should be followed at every major engine
generator for one hour. This will allow the grease
overhaul:
to expand. The expanding grease will force the
excess grease from the cavity. When the excess
grease is forced from the cavity, the internal
pressure will be reduced. The generator should
continue to operate until the grease stops purging.

5. Stop the engine. Install the bracket drain plug.

Wipe off the excess grease.
SEBU7828-10 155
Maintenance Section
Generator Bearing - Lubricate

6. For greasing intervals, follow the recommendations

on the lubrication plate (if equipped) or refer to
Maintenance Schedule, “Generator Bearing -
Lubricate”. Whenever the bearings are greased,
repeat Step 1. DO NOT MIX GREASES.

i03997526

Generator Bearing - Lubricate

SMCS Code: 4471-086

Lubricating Process (If Applicable)

Note: If the generator already has a visible grease
point, go to Step 4.

1. Remove either the louver assembly or the rear

plate from the rear of the generator housing.

2. Remove the top grease pipe plug and remove the

lower grease pipe plug.

3. Install a grease fitting in the grease pipe.

4. Grease the bearings with the appropriate grease

from Table 28. Do not mix greases.

Table 28
Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
108-1760 321 BC 680 −29 °C 2S-3230 Every 2000 51.2 g 59 mL 105.0 mm
Ball Bearing 225.0 mm (−20.2 °F) Bearing service (1.8 oz) (2 oz) (4.1 inch)
(8.9 inch) minimum Lubricant hours or 12
OD / months
80 °C
105.0 mm (176 °F)
(4.1 inch) ID maximum
108-1761 322 BC 690 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL 110.0 mm
Ball Bearing 240.0 mm 800 (−20.2 °F) Bearing service (1.8 oz) (2 oz) (4.3 inch)
(9.4 inch) / Lubricant hours or 12
OD 80 °C months
(176 °F)
110.0 mm
(4.3 inch) ID
139-0349 Roller 2900 / −40 °C Mobilith Every 250 2.8 g NA 127.0 mm
Roller 2800 (−40 °F) SHC220 service (0.1 oz) (5.0 inch)
Bearing / hours
80 °C
(176 °F)
139-0350 Roller 2900 / −40 °C Mobilith Every 250 2.8 g NA 127.0 mm
Roller 2800 (−40 °F) SHC220 service (0.1 oz) (5.0 inch)
Bearing / hours
80 °C
(176 °F)
(continued)
156 SEBU7828-10
Maintenance Section
Generator Bearing - Lubricate

(Table 28, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
154-3032 326 BC 820 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL 130.0 mm
Ball Bearing 280.0 mm 2600 / (−20.2 °F) Bearing service (1.8 oz) (2 oz) (5.1 inch)
(11.0 inch) 2700 / Lubricant hours or 12
OD 80 °C months
(176 °F)
130.0 mm
(5.1 inch) ID
241-4644 320 BC LC7 −29 °C UNIREX Every 4500 60 g NA 100.0 mm
Bearing 215.0 mm (−20.2 °F) N3 service (2.1 oz) (3.9 inch)
(8.5 inch) / hours or 12
OD 60 °C months
(140 °F)(2)
100.0 mm
(3.9 inch) ID
243-5220 315 BB LC6100 −29 °C UNIREX Non- Non- Non- 75.0 mm
Bearing 160.0 mm / (−20.2 °F) N3 regreasable regreasable regreasable (3.0 inch)
(6.3 inch) LC5000 / bearing(3) bearing bearing
OD 60 °C
(140 °F)(2)
75.0 mm
(3.0 inch) ID
261-3545 307 BB LC2000 −29 °C UNIREX Non- Non- Non- 35.0 mm
Bearing 80.0 mm (−20.2 °F) N3 regreasable regreasable regreasable (1.4 inch)
(3.1 inch) / bearing(3) bearing bearing
OD 50 °C
(122 °F)(2)
35.0 mm
(1.4 inch) ID
262-5921 307 BC LC2000 −29 °C UNIREX Non- Non- Non- 35.0 mm
Bearing 80.0 mm (−20.2 °F) N3 regreasable regreasable regreasable (1.4 inch)
(3.1 inch) / bearing(3) bearing bearing
OD 60 °C
(140 °F)(2)
35.0 mm
(1.4 inch) ID
263-0161 309 BC LC3000 −29 °C UNIREX Non- Non- Non- 45.0 mm
Bearing 100.0 mm (−20.2 °F) N3 regreasable regreasable regreasable (1.8 inch)
(3.9 inch) / bearing(3) bearing bearing
OD 60 °C
(140 °F)(2)
45.0 mm
(1.8 inch)
5P-2448 315 BC 580 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL 75.0 mm
Ball Bearing 160.0 mm 590 (−20.2 °F) Bearing service (1.8 oz) (2 oz) (3.0 inch)
(6.3 inch) / Lubricant hours or 12
OD 80 °C months
(176 °F)
75.0 mm
(3.0 inch) ID
6Y-3955 220 BC 450 −29 °C 2S-3230 Every 2000 51.2 g 59 mL 100.0 mm
Ball Bearing 180.0 mm (−20.2 °F) Bearing service (1.8 oz) (2 oz) (3.9 inch)
(7.1 inch) / Lubricant hours or 12
OD 80 °C months
(176 °F)
100.0 mm
(3.9 inch) ID
(continued)
SEBU7828-10 157
Maintenance Section
Generator Bearing - Lubricate

(Table 28, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
6Y-6488 318 BC 597 −29 °C 2S-3230 Every 2000 51.2 g 59 mL 90.0 mm
Ball Bearing 190.0 mm (−20.2 °F) Bearing service (1.8 oz) (2 oz) (3.5 inch)
(7.5 inch) / Lubricant hours or 12
OD 80 °C months
(176 °F)
90.0 mm
(3.5 inch)
311-0843 326 BC 1800 −40 °C EA6 Non- Non- Non- 130.0 mm
Ball Bearing 280.0 mm FR (−40 °F) regreasable regreasable regreasable (5.1 inch)
(11.0 inch) / bearing(1) bearing bearing
OD 80 °C
(176 °F)
130.0 mm
(5.1 inch) ID
311-0844 322 BC 1600 −40 °C EA6 Non- Non- Non- 110.0 mm
Ball Bearing 240.0 mm FR (−40 °F) regreasable regreasable regreasable (4.3 inch)
(9.4 inch) / bearing(1) bearing bearing
OD 80 °C
(176 °F)
110.0 mm
(4.3 inch) ID
253-9789 320 BC 1400 −29 °C UNIREX Non- Non- Non- 100.0 mm
Bearing 215.0 mm FR (−20.2 °F) N3 regreasable regreasable regreasable (3.9 inch)
(8.5 inch) / bearing(1) bearing bearing
OD 80 °C
(176 °F)
100.0 mm
(3.9 inch) ID
193-4070 018 BC 498/ −29 °C 2S-3230 Every 2000 51.2 g 59 mL 90.0 mm
Ball Bearing 140.0 mm 499 (−20.2 °F) Bearing service (1.8 oz) (2 oz) (3.5 inch)
(5.5 inch) / Lubricant hours or 12
OD 80 °C months
(176 °F)
90.0 mm
(3.5 inch) ID
(1) This temperature is for a generator set that is equipped with a resistive temperature detector (RTD).
(2) Do not exceed 60 °C (140 °F) above the ambient temperature.
(3) This bearing cannot be greased. Refer to this Operation and Maintenance Manual, “Generator Bearing - Replace” article for information
concerning the replacement of these bearings.
(2) Do not exceed 50 °C (122 °F) above the ambient temperature.

5. Wipe off the excess grease. Remove the top Additional Information
grease fitting. Install the plug.
Refer to Special Instruction, REHS4892, “Generator
6. Operate the generator for 1 hour. This process Bearing Service” for further information.
will allow the grease to expand. The expanding
grease will force the excess grease from the
cavity. When the excess grease is forced from
the cavity, the internal pressure will be reduced.
The generator should continue to operate until the
grease stops purging.

7. Stop the engine. Install the plug in the bottom

grease pipe. Wipe off the excess grease.

8. Install the louver assembly or install the rear plate.

158 SEBU7828-10
Maintenance Section
Generator Bearing Temperature - Test/Record

i03642839 i04032220

Generator Bearing Generator Lead (Flat Braided

Temperature - Test/Record Cable) - Check
SMCS Code: 4471-081-TA SMCS Code: 4450-535

The monitoring of bearing temperature may prevent

premature bearing failure. A generator set should
never operate above the recommended set points.
Keep records in order to monitor the changes in the
temperature of the bearing.

Note: Measure the bearing temperature after the

generator reaches normal operating temperature.

Resistive Temperature Detectors

(RTDs)
Caterpillar Generators may be equipped with
resistance temperature detectors for generator
bearings. These detectors are 100 ohm resistance
temperature detectors. A resistance temperature
detector may be monitored by the optional monitor for
the EMCP 3.2/3.3 resistance temperature detector. A
resistance temperature detector may be monitored by
equipment that is provided by the customer. Consult Illustration 103
g02146533
with your Caterpillar dealer about other methods of
Typical flat braided conductor
measuring the bearing temperature.

The EMCP 3.2/3.3 may be configured to “ALARM”
or the EMCP 3.2/3.3 may be configured to
“SHUTDOWN”. An alarm is activated if the
temperature of the bearing reaches 85 °C (185 °F).
A shutdown occurs if the temperature of the bearing
reaches 95 °C (203 °F).
Infrared Thermometers
Bearing temperatures can also be recorded with the
use of an infrared thermometer. Refer to Special
Publication, NENG2500, “Caterpillar Dealer Service
Tools Catalog” for a variety of infrared thermometers.
Follow the instructions that come with your infrared
thermometer.
The generator set may have braided square
conductors or multiple round cables between the
generator and the breaker.
Check braided conductors for signs of wear. Pay
particular attention to the conductor protective sleeve
insulation at the housing for the breaker and in the
generator terminal box. Replace the mats or the
cable immediately if the rubber mats or the insulation
on the braided cables show signs of wear at points of
contact. If your generator set does not have rubber
mats in place, contact your Cat dealer.
i04032349
Generator Lead (Round Cable)
- Check
SMCS Code: 4450-535

The generator set may have braided square

conductors or multiple round cables between the
generator and the breaker.
SEBU7828-10
g02223453
Illustration 104
Round generator lead cables
Ensure that the generator output leads are routed out
of the generator in a manner that prevents the leads
from rubbing against metal objects. Visually inspect
the following areas for cracking and physical damage:
• Stator output leads
• Protective sleeving
• Insulation
i01228480
Generator Load - Check
SMCS Code: 4450-535-LA
During normal operation, monitor the power factor
and monitor generator loading.
When a generator is installed or when a generator
is reconnected, ensure that the total current in any
one phase does not exceed the nameplate rating.
Each phase should carry the same load. This allows
the generator to work at the rated capacity. If one
phase current exceeds the nameplate amperage,
an electrical imbalance will occur. An electrical
imbalance can result in an electrical overload and an
electrical imbalance can result in overheating .
The power factor can be referred to as the efficiency
of the load. This can be expressed as the ratio of kVA
to actual kW. The power factor can be calculated by
dividing kW by kVA. Power factor is expressed as a
decimal. Power factor is used to mean the portion
of current that is supplied to a system that is doing
useful work. The portion of the current that is not
doing useful work is absorbed in maintaining the
magnetic field in motors. This current (reactive load)
can be maintained without engine power.
159
Maintenance Section
Generator Load - Check
Electric sets normally have a low idle setting that
is higher than industrial engines. Low idle will be
approximately 66% of the full speed that is achieved
by 60 Hz units. This would be equal to 80% of the full
speed that is achieved by 50 Hz units.
Some electric sets are equipped with Woodward
governors and some electric sets are equipped
with Caterpillar electronic governors. These electric
sets have no low idle stop. On electric sets with
mechanical governors and natural gas electric sets,
the low idle is set at the factory. Adjustment of the
low idle on these machines should only be done by
a Caterpillar dealer.
Note: Operating the electric set at low idle speed for
an extended time will cause some voltage regulators
to shut off. The electric set must be completely shut
down and the electric set must be restarted. This
will allow the voltage regulator to again produce an
output.
i01593517
Generator Set - Test
SMCS Code: 4450-081
Personal injury or death can result from high volt-
age.
When power generation equipment must be in op-
eration to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
When servicing or repairing electric power gener-
ation equipment:
• Make sure the unit is off-line (disconnected
from utility and/or other generators power
service), and either locked out or tagged DO
NOT OPERATE.
• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
160 SEBU7828-10
Maintenance Section
Generator Set Alignment - Check

Table 29 i03956450

Tools Needed Generator Set Alignment -

Part Number Part Quantity Check
6V-7070
Digital
Multimeter
1 (Generator Sets)
12 VDC battery 1 SMCS Code: 7002-024
Potential
Transformer
1 The genset must be aligned when the genset is
installed or moved into a different position. If the
generator set is run at the full continuous rating, the
The generator set functional test is a simplified test alignment of the generator to the engine must be
that can be performed in order to determine if the checked annually.
generator is functional. The generator set functional
test should be performed on a generator set that is Properly maintain the alignment between the engine
under load. and the driven equipment in order to minimize the
following problems:
The generator set functional test determines if the
following statements happen: • Bearing problems
• A phase voltage is being generated. • Vibration of the engine crankshaft
• The phase voltages are balanced. • Vibration of the driven equipment
• The phase voltages change relative to engine Refer to the following information for more information
speed. about the alignment of the generator set:

The generator set functional test consists of the • Special Instruction, SEHS7654, “Alignment -
following steps: General Instructions”

1. Stop the generator. Connect the potential
transformer's high voltage winding to the
generator terminals (T1) and (T2). Connect
the voltmeter to the low voltage winding. If two
transformers are available, connect the high
voltage winding of the second transformer to the
generator terminals (T1) and (T3). Connect the
secondary terminals that correspond to generator
terminal (T2) of both transformers together.
2. Disconnect wires “E+” and “E-” from the voltage
regulator. Disconnect the generator from the load.
3. Connect a 12 VDC automotive battery to wires
“E+” and “E-”.
4. Measure the AC voltage across the low voltage
terminals of the transformer that correspond to the
following generator terminals: “T1” and “T2”, “T2”
and “T3”, and “T3” and “T1”. Record the voltages.
• Special Instruction, SEHS7259, “Alignment of
Single Bearing Generators”
• Special Instruction, REHS0177, “Alignment of the
Close Coupled Two Bearing Generators”
Keep a record of the measurement of the alignment.
The record may be used to check the trend of the
alignment. The record may be used to analyze the
trend of the alignment.
i01228545
Generator Set Vibration -
Inspect
SMCS Code: 4450-040-VI
Check for vibration damage. Vibration may cause the
following problems:

• loose fittings
• loose bolts
• excessive noise
• cracked insulation
SEBU7828-10 161
Maintenance Section
Generator Set Vibration - Test/Record

The following areas are susceptible to vibration • Exposed electrical connections

damage:
• Transformers
• stator output leads
• Fuses
• protective sleeving
• Capacitors
• insulation
• Lightning arresters
• exposed electrical connections
When a generator set is installed, a vibration plot
• transformers should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
• fuses updated yearly. The vibration plot should also be
updated when the generator set is moved and
• capacitors when the engine is overhauled. This will allow
the trend of the vibration to be monitored and
• lightning arrestors analyzed. A potential problem may be prevented by
monitoring the trend of the vibration. If the vibration
Check the generator set's vibration level by using a is approaching the limit of the specification of the
broad spectrum analyzer. component, the problem may be more imminent.
Refer to Data Sheet, LEKQ4023, “Linear Vibration”
for the allowable limits of vibration.
i03643886

Generator Set Vibration - Caterpillar also recommends recording the vibration

of the bearing at the generator bearing bracket.
Test/Record
If the vibration exceeds the EDS limits for vibration,
SMCS Code: 4450-081-VI check the alignment. Refer to this Operation and
Maintenance Manual, “Generator Set Alignment -
Check for vibration damage. Check” for the alignment procedure.

Vibration may cause the following problems: Contact the Caterpillar Dealer Service Tools group
for information on ordering a vibration analyzer that
• Coupling wear will meet your needs.

• Loose fittings
i03847809

• Fatigue of the metal components of the engine Hoses and Clamps -

• Cracks in the cabinet which surrounds the Inspect/Replace
generator
SMCS Code: 7554-040; 7554-510
• Cracks in welds
Hoses and clamps must be inspected periodically
• Excessive noise in order to ensure safe operation and continuous
operation of the engine. Take proper safety
• Cracked insulation precautions before inspecting or replacing hoses and
clamps.
The following areas are susceptible to vibration
damage: Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking
• Coupling for the generator set fluid that is under pressure can cause serious
injury or possible death. This includes leaks that
• Generator bearings are the size of a pin hole. Refer to Operation and
Maintenance Manual, “General Hazard Information”
• Stator output leads for more information.

• Protective sleeving
• Insulation
162
Maintenance Section
Hoses and Clamps - Inspect/Replace
Inspect the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which exhibits
any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
may result in a hazardous situation.
• Hoses which are cracked
• Hoses which are soft
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
• Hoses which exhibit signs of leakage which are not
the result of loose couplings or clamps
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking
• Looseness
• Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
hose clamps which are loose.
SEBU7828-10
Replace the Hoses and the Clamps
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Cooling System
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system in order to relieve
any pressure.
4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.
6. Remove the hose clamps.
SEBU7828-10
7. Disconnect the old hose.
8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
10. Refill the cooling system.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap
if the gaskets are damaged. Install the filler cap.
12. Start the engine. Inspect the cooling system for
leaks.
Fuel System
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
163
Maintenance Section
Hoses and Clamps - Inspect/Replace
Note: High pressure fuel lines may be installed
between the high pressure fuel pump and the fuel
injectors. High pressure fuel lines are constantly
charged with high pressure. Do not check the high
pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
engine stops before you perform any service or repair
on high pressure fuel lines in order to allow pressure
to be purged.
1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
2. Remove the hose clamps.
3. Disconnect the old hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
engine.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.
Lubrication System
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
2. Remove the hose clamps.
3. Disconnect the old hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
164
Maintenance Section
Instrument Panel - Inspect
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, “Engine
Oil Level - Check” in order to ensure that the
lubrication system is filled with the proper amount
of engine oil.
7. Start the engine. Inspect the lubrication system
for leaks.
Air System
1. Remove the hose clamps.
2. Disconnect the old hose.
3. Replace the old hose with a new hose.
4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
5. Start the engine. Inspect the air lines for leaks.
i01917577
Instrument Panel - Inspect
SMCS Code: 7451-040
Inspect the instrument panel for good condition.
Perform the self test. All of the warning lamps should
illuminate. If a warning lamp does not illuminate,
replace the bulb immediately. If the alarm does
not sound, investigate the problem and correct the
problem.
Check the condition of all of the gauges. If a gauge
is broken, repair the gauge or replace the gauge
immediately.
Frequently monitor the gauges during normal
operation.
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
the new data to the recorded data will help to
establish the trends of engine performance. A gauge
reading that is abnormal may indicate a problem with
operation or a problem with the gauge.
SEBU7828-10
i01951994
Insulation - Test
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081
Recommended Periodic Insulation
Tests
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Table 30
Tools Needed
142-5055 Insulation Testing Gp
9U-6003 Insulation Testing Gp
Periodically, use an insulation tester to check the
insulation resistance of the generator's main stator
winding. The frequency of this test is determined by
the generator's environment. Previous insulation
tester readings will also determine the frequency of
this test.
Test the main stator windings with an insulation tester
in the following situations:
• The generator set is started for the first time.
• The generator set is removed from storage.
• The generator set is operating in a humid
environment. Test every three months.
• The generator set is not protected from the
elements in an enclosed area. Test every three
months.
• The generator set is installed in an enclosed area.
This area needs to be low in humidity and this area
needs to have steady temperatures. Test every
twelve months (minimum).
SEBU7828-10
• The generator set has not been run under load
for three months. Test the generator set weekly.
Use space heaters around the generator set if the
generator is exposed to a sea water environment or
if the humidity is above 75 percent. Also use space
heaters if a test result was below 3 megohms.
Space heaters must be used whenever the generator
set is not under load. Space heaters must also be
used whenever salt is present or whenever high
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester
readings above one megohm. Use space heaters
only when the generator is not running.
For additional information, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Recommended Procedure for A
Periodic Insulation Test
Personal injury or death can result from electro-
cution.
The megohmmeter is applying a high voltage to
the circuit.
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When
finished testing also discharge the generator
windings.
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If
moisture exists, do not perform this insulation
test. Dry the unit first. Refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Isolate the stator windings of the generator by
disconnecting all other leads and cables from the
generator terminals. This includes connections
to the voltage regulator, the control panel, the
switchgear or other devices.
6. Connect the insulation tester's RED lead to
ground.
7. Connect the insulation tester's BLACK lead to the
wye point or star point of the generator's windings.
165
Maintenance Section
Insulation - Test
8. For units that are 600 volts or less, set the voltage
to 500 Volts. For units that are more than 600
volts, set the voltage to 1000 Volts.
9. Use the 30/60 Time Resistance Method:
a. Apply voltage.
b. Observe the readings at 30 seconds. Observe
the readings at 60 seconds.
c. Record the 60 second reading. This reading
must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.
10. Evaluate the readings. The actual value of the
resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
conditions. If a 60 second resistance reading
has a 50 percent reduction from the previous
reading, the insulation may have absorbed too
much moisture.
Switch the insulation tester to the “OFF” position.
This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.
Note: The results from the insulation resistance
checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance
will vary greatly with temperature. Therefore, always
test at the same temperature and humidity. Refer to
Illustration 105.
Serial Number (Engine)___________________________________
Serial Number (Generator)_______________________________
166 SEBU7828-10
Maintenance Section
Insulation - Test

g00633226
Illustration 105
SEBU7828-10 167
Maintenance Section
Jacket Water Heater - Check

i01917546 1. Remove the magnetic pickup (1) from the flywheel

housing. Check the condition of the end of the
Jacket Water Heater - Check magnetic pickup. Check for signs of wear and
(Standby Generator Sets (If contaminants.

Equipped)) 2. Clean the metal shavings and other debris from

the face of the magnet.
SMCS Code: 1383-535
3. Install the magnetic pickup and adjust the
Jacket water heaters help to improve startability in magnetic pickup. Refer to the Service Manual for
ambient temperatures that are below 21 °C (70 °F). the installation procedure.
All installations that require automatic starting should
have jacket water heaters.
i02436705
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater Overhaul Considerations
should maintain the jacket water coolant temperature
at approximately 32 °C (90 °F). SMCS Code: 7595-043

Reduced hours of operation at full load will result in

i00850920 a lower average power demand and reduced fuel
consumption. A decreased average power demand
Magnetic Pickups - should increase both the engine service life and the
Clean/Inspect overhaul interval.

SMCS Code: 1907-040; 7400-040; 7400-070
The need for an overhaul is generally indicated
by increased fuel consumption, increased oil
consumption, excessive engine blowby, and
reduced power. Arctic temperatures, extremely high
temperatures, corrosive environments, or extremely
dusty conditions contribute to premature wear and
the need for an overhaul.

The following factors are important when a decision

is being made on the proper time for an engine
overhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used
Illustration 106
g00422322 • The operating conditions
(1) Magnetic pickup. (2) Flywheel housing.
• The results of the S·O·S analysis

Oil Consumption as an Overhaul

Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.

Oil consumption is in proportion to the percentage

of the rated engine load. As the percentage of the
Illustration 107
g00293337 engine load is increased, the amount of oil that is
consumed per hour also increases.
Typical magnetic pickup
168
Maintenance Section
Overhaul Considerations
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
standards for reusable parts.
• The engine's service life can be extended without
the risk of a major catastrophe due to engine
failure.
• The best cost/value relationship per hour of
extended life can be attained.
After Failure Overhaul
If a major engine failure occurs and the engine
must be removed, many options are available. An
overhaul should be performed if the engine block or
the crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
• Specially designed Caterpillar engine features
• Caterpillar dealer exchange components
• Caterpillar Inc. remanufactured exchange
components
Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you
with the best cost/value relationship.
SEBU7828-10
Note: Overhaul programs vary according to the
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following
maintenance recommendations.
Rebuild or Exchange
Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump
These components should be inspected according to
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
• Salvaging
• Repairing
• Replacing
Using out-of-spec parts can result in the following
problems:
• Unscheduled downtime
• Costly repairs
• Damage to other engine parts
• Reduced engine efficiency
• Increased fuel consumption
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
Inspection and/or Replacement
Crankshaft Bearings, Valve Rotators, and
Crankshaft Seals
The following components may not last until the
second overhaul.
SEBU7828-10 169
Maintenance Section
Overhaul Considerations

• Thrust bearings
NOTICE
• Main bearings Do not use caustic cleaners to clean the core.

• Rod bearings Caustic cleaners can attack the internal metals of the
core and cause leakage.
• Valve rotators
• Crankshaft seals Note: Use this cleaning procedure to clean the oil
cooler core.
Caterpillar Inc. recommends the installation of new
parts at each overhaul period. 1. Remove the oil cooler core.

Inspect these parts while the engine is disassembled 2. Remove any debris from the oil cooler core. To
for an overhaul. remove debris from the oil cooler core, turn the oil
cooler core onto one end.
Inspect the crankshaft for any of the following
conditions: 3. Flush the oil cooler core internally with cleaner in
order to loosen foreign substances. This will also
• Deflection help to remove oil from the oil cooler core.

• Damage to the journals Note: Caterpillar Inc. recommends the use of

Hydrosolv Liquid Cleaners. Table 31 lists the
• Bearing material that has seized to the journals Hydrosolv Liquid Cleaners that are available from
your Caterpillar dealer.
Check the journal taper and the profile of the
Table 31
crankshaft journals. Check these components by
interpreting the wear patterns on the following HydrosolvLiquid Cleaners
components:
Part
Description Size
Number
• Rod bearing
1U-8812 4 L (1 US gallon)
• Main bearings 1U-5490 Hydrosolv4165 19 L (5 US gallon)
Inspect the camshaft for damage to the journals and 8T-7570 208 L (55 US gallon)
to the lobes. 1U-8804 4 L (1 US gallon)
Note: If the camshaft is removed for any reason, use 1U-5492 Hydrosolv100 19 L (5 US gallon)
the magnetic particle inspection process to check for 8T-5571 208 L (55 US gallon)
cracks in the camshaft.

Inspect the following components for signs of wear or 4. Use steam to clean the oil cooler core. This
for signs of scuffing: removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
• Camshaft bearings other trapped debris.

• Camshaft followers 5. Wash the oil cooler core with hot, soapy water.
Rinse the oil cooler core thoroughly with clean
Caterpillar Inc. recommends replacing the crankshaft water.
vibration damper.

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommends the
removal of the oil cooler core. Clean the oil cooler
core. Then, pressure test the oil cooler core.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
170
Maintenance Section
Power Factor - Check
6. Dry the oil cooler core with compressed air. Direct
the air in the reverse direction of the normal flow.
7. Inspect the components in order to ensure
cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core.
For more information about cleaning the cores,
consult your Caterpillar dealer.
Obtain Coolant Analysis
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
is overhauled.
For example, considerable deposits are found in the
water jacket areas on the external cooling system, but
the concentrations of coolant additives were carefully
maintained. The coolant water probably contained
minerals that were deposited on the engine over time.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or
an agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2) provides
the following information:
• Complete S·O·S Coolant Analysis (Level 1)
• Visual inspection of properties
• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see
your Caterpillar dealer.
SEBU7828-10
i01191656
Power Factor - Check
SMCS Code: 4450-535-PWR
The power factor of a system can be determined by
a power factor meter or by calculations. The power
factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal.
i04020194
Radiator - Clean
SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between
the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
SEBU7828-10 171
Maintenance Section
Rotating Rectifier - Check

After cleaning, start the engine and accelerate the
engine to high idle rpm. This procedure will help in
the removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to
inspect the core for cleanliness. Repeat the cleaning,
if necessary.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
1. Stop the generator set. Disconnect the wires for
the AVR and isolate the wires for the AVR.
2. Make an assembly for separate excitation. The
assembly can use a 12 volt battery or a variable
DC power supply as a power source. Refer to
Step 3 for an assembly that uses a 12 Volt battery.
Refer to Step 4 for an assembly that uses a
variable DC power supply.

i01880286

Rotating Rectifier - Check

SMCS Code: 4465-535

The high voltage that is produced by an operating

generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start. Illustration 108
g01015807

(A) Exciter Field

Place the engine control switch in the “OFF” posi- (B) Diode (1 Amp)
tion. Attach “DO NOT OPERATE” tags to all start- (C) Rheostat (50 Ohms 300 Watts)
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and 3. Connect a 12 volt battery in series with a rheostat
automatic transfer switches that are associated (C) of “50 Ohms 300 Watts” and a diode (B) on
with the generator. both wires for the exciter field (5+ and 6-). Go to
step 5.
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
refer to Maintenance Procedure, “Rotating Rectifier -
Test”.

i01936391

Rotating Rectifier - Test

SMCS Code: 4465-081

The high voltage that is produced by an operating g01015808

Illustration 109
generator set can cause severe injury or death.
Before performing any maintenance or repairs, (D) AC supply
(E) Variable power supply
ensure that the generator will not start. (F) Exciter field
(G) Diode bridge
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start- 4. Connect a variable power supply and a diode
ing controls. Disconnect the batteries or disable bridge to both of the wires for the exciter field (5+)
the starting system. Lock out all switchgear and and (6-).
automatic transfer switches that are associated
with the generator. 5. The assembly should have characteristics that are
compatible with the power for the field excitation
Use the following procedure in order to test the of the generator.
rotating rectifier.
172
Maintenance Section
Severe Service Application - Check
6. Operate the generator set at rated speed.
7. Gradually increase the current of the exciter field
by adjusting the rheostat or the variable power
supply. Measure the output voltage and the
current at no load. Measure the output voltage
and measure the current at no load.
8. The generator is operating properly when the
output voltage is at the rated value and the output
voltage is balanced within one percent for the
rated level of excitation.
i03937573
Severe Service Application -
Check
SMCS Code: 1000-535
An engine which operates outside of normal
conditions is operating in a severe service
application.
An engine that operates in a severe service
application may need more frequent maintenance
intervals in order to maximize the following conditions:
• Reliability
• Service life
The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your
Caterpillar dealer for the unique maintenance that
may be necessary for your engine.
An application is a severe service application if any
of the following conditions apply:
Severe Environmental Factors
• Frequent operation in dirty air
• Frequent operation at an altitude which is above
1525 m (5000 ft)
• Frequent operation in ambient temperatures which
are above 32° C (90° F)
• Frequent operation in ambient temperatures which
are below 0° C (32° F)
Severe Operating Conditions
• Frequent operation with inlet air which has a
corrosive content
SEBU7828-10
• Operation with inlet air which has a combustible
content
• Operation which is outside of the intended
application
• Operation with a plugged fuel filter
• Extended operation at low idle (more than 20% of
hours)
• Frequent cold starts at temperatures below 0° C
(32° F)
• Frequent dry starts (starting after more than 72
hours of shutdown)
• Frequent hot shutdowns (shutting down the engine
without the minimum of 2 minutes to 5 minutes of
cool down time)
• Operation above the engine rated speed
• Operation below the peak torque speed
• Operating with fuel which does not meet
the standards for distillate diesel fuel as
stated in Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids
Recommendations”, “Distillate Diesel Fuel”
• Operating with fuel which contains greater than
1000 ppm (0.1%) sulfur
• Operating with a blend of distillate fuel which
contains more than 5 percent biodiesel
Improper Maintenance Procedures
(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks from
causes such as excessive water, sediment, and
microorganism growth.
• Extending maintenance intervals beyond the
recommended intervals
• Using fluids which are not recommended in Special
Publication, SEBU6251, “Caterpillar Commercial
Diesel Engine Fluids Recommendations”
• Extending maintenance intervals for changing
the engine oil and engine coolant without S·O·S
validation
• Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
SEBU7828-10
• Failure to use a water separator
• Using filters which are not recommended by
Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
• Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
refer to Special Publication, SEHS9031, “Storage
Procedure for Caterpillar Products”)
• Storing the engine for 1 yr to 2 years (For
information about engine storage, refer to Special
Instruction, SEHS5001, “The Long Term Storage
and Recovery of Certain Commercial Engines”)
i02501318
Space Heater - Check
SMCS Code: 4450-535-HTR
A Caterpillar generator is capable of operating in
high humidity conditions without problems. However,
problems can occur when the generator is idle and
the surrounding air is warmer than the generator.
Moisture can form on the windings that will result in
poor performance from the windings. Moisture can
also result in damage to the windings. Whenever the
generator is not active, ensure that the space heaters
are in operation.
Table 32
Tools Needed
Part Number Part Quantity
237-5130
Digital
1 Procedures
Multimeter
1. Stop the generator set.
2. Remove the panels in order to allow access to
the regulator and control terminal strips. Locate
terminal strip “TS1”.
3. For 240 V systems, use the multimeter to measure
the voltage between terminal “H1” and terminal
“H4”. If voltage is not present, disconnect the
power source to terminal “H1” and terminal “H4”,
and check for 3 to 12 ohms resistance. If there is
no resistance, check the generator service manual
for further information. For 120 V systems, use
the multimeter to measure the voltage between
terminal “H1” and terminal “H2”. If voltage is not
present, disconnect the power source to terminal
“H1”, terminal “H2”, terminal “H3”, and terminal
“H4”, and check for 3 to 12 ohms resistance. If
there is no resistance, check the generator service
manual for further information.
173
Maintenance Section
Space Heater - Check
i03108463
Standby Generator
Set Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may not need to be used
very often. However, the generator set is usually
needed for operation in an emergency situation.
Maintenance of the standby generator set is very
important for the following reasons:
• The generator set must always be in excellent
operating condition.
• The generator set must be ready to work under
load at any time.
Establishing a Preventive Maintenance Program will
provide these benefits:
• Maximum availability of the standby generator set
• Longer service life for the generator set
• Minimum of expensive repairs
Your Caterpillar dealer can help you to establish an
effective Preventive Maintenance Program for your
generator set. Consult your Caterpillar dealer for
details.
Maintenance and Operation
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
The recommended maintenance for the generator set
is listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule (Standby Generator
Sets)” (Maintenance Section).
174
Maintenance Section
Starting Motor - Inspect
Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the
subsequent maintenance intervals must be
performed by an authorized service technician or by
your Caterpillar dealer.
Unless other instructions are provided, perform
maintenance and repairs under the following
conditions:
• The engine is stopped.
• The starting system is disabled.
• The generator does not pose an electrical shock
hazard.
• The generator is disconnected from the load.
Operation
To ensure proper operation, the generator set must be
exercised regularly. For instructions on operating the
generator set, see the Operation and Maintenance
Manual for the generator set control panel.
For these operation procedures, follow the
instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting
the engine, engine operation, and stopping the
engine.
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems, and repairs.
Space Heaters
Moisture causes damage to generators and other
electrical equipment. Make every effort to keep the
generator set as dry as possible.
Generators can operate without problems in humid
environments. However, problems can occur when
the generator is inactive. Moisture can condense on
the windings. This can result in poor performance.
Also, damage to the windings can occur.
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the
space heaters are operating. When the generator is
operating, turn OFF the space heaters.
SEBU7828-10
i00651416
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
i03230840
Stator Lead - Check
SMCS Code: 4459-535
Ensure that the stator output leads are routed out of
the generator in a manner that prevents the leads
from rubbing against metal objects.
Visually inspect the following areas for cracking and
physical damage:
• stator output leads
• protective sleeving
• insulation
i03086301
Stator Winding Temperature -
Measure/Record
SMCS Code: 4453-082-TA
Some generators are equipped with optional 100
Ohm Resistance Temperature Detectors(RTD) that
are mounted in slots of the main stator. When the
generator set is equipped with RTD modules that
are interfaced to an EMCP 3.2 or EMCP 3.3, the
RTD modules can be interfaced in order to measure
the temperature of the stator. Alternately, there are
measuring devices in the open market that can be
interfaced with the RTD. Caterpillar recommends the
continuous monitoring of the RTD.
Refer to the specifications in table 33 for the
maximum temperatures of the setpoints.
SEBU7828-10
Table 33
Maximum Recommended Temperatures
for the Setpoint(1)
Generator set
Alarm Shutdown
application
Standby 180 °C 190 °C
(356 °F) (374 °F)
Continuous 155 °C 165 °C
(311 °F) (329 °F)
(1)
If the trend of the operating temperature of the main stator
is measured and the temperature is much lower than the
recommended setpoints, adjust the alarm setpoint and the
shutdown setpoint to a lower value in order to ensure that
unusual temperature variances are recognized promptly.
i01539769
Turbocharger - Inspect
SMCS Code: 1052-040; 1052
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
175
Maintenance Section
Turbocharger - Inspect
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
Removal and Installation
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
from entering during reassembly.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for
corrosion.
176
Maintenance Section
Varistor - Check
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i03291822
Varistor - Check
SMCS Code: 4466-535
The varistor must be checked at regular intervals.
Refer to Systems Operation/Testing and Adjusting,
KENR5284, “Varistor - Test” for instructions.
i03291802
Varistor - Inspect
SMCS Code: 4466-040
The varistor must be visually inspected at regular
intervals. For generator sets with 1400 or with
1600 frames, discoloration of the varistor indicates
that replacement of the varistor is necessary. For
generator sets with 1800 frames, physical signs of
failure indicate that replacement of the varistor is
necessary.
i01491868
Voltage and Frequency - Check
SMCS Code: 4450-535-EL
Check for the proper voltage setting and check for
the proper frequency setting. Check for stability.
For the correct voltage and frequency, refer to the
generator set's Serial Plate.
i01908686
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
SEBU7828-10
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
• Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pump and the installation of water pump and/or
seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
SEBU7828-10 177
Maintenance Section
Water Pump - Inspect

• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection and
for good condition.
Cracking – Cracking of insulation may result from
mechanical stress. The structure that is used to brace
the stator winding will become loose if the problem
is not corrected. Further mechanical damage or
electrical damage may also result.
Erosion – Erosion can be caused when foreign
substances rub against the surfaces of the insulation.
i03543200

• Inspect the engine-to-frame ground strap for a

good connection and for good condition.
• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges which are cracked or replace any gauges
that can not be calibrated.
Inspect the Insulation
A visual inspection should be initially directed at
the areas that are most prone to damage and
deterioration. The most prone areas to damage and
deterioration are listed below:
• Ground Insulation. Ground insulation is insulation
that is intended to isolate components that are
carrying current from components that are not
carrying current.
• Support Insulation. Support insulation is
usually made from one of the following items:
a compressed lamination of fibrous materials,
polyester, or felt pads that have been impregnated
with various types of bonding agents.
There are many different types of damage that can
occur in these areas. Several of the different types of
damage are listed below:
Water Pump - Inspect
SMCS Code: 1361-040; 1361
A failed water pump might cause severe engine
overheating problems that could result in the following
conditions:
• Cracks in the cylinder head
• A piston seizure
• Other potential damage to the engine
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
- Disassemble and Water Pump - Assemble” for
the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
“Water Pump - Remove and Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
replacement is needed.

Thermal Aging – Thermal aging can cause the

degradation of insulation or the deterioration of
insulation. An examination of the coils may reveal
that the insulation has expanded into the ventilation
ducts. This is the result of a loss of bond which
will cause the insulation material to separate. The
insulation material could also separate from the
conductors on the windings.

Abrasion – The surfaces of coils and the surfaces

of connectors may be damaged by abrasion. These
surfaces may also be damaged by contamination
from other sources. An example of these sources
would be chemicals or abrasive substances.